Tooling System With Array of Height Adjustable Elements

ABSTRACT

A tooling system ( 1 ) having a number of elements ( 2 ) arranged in an array, which elements define a contoured surface, or a section of a contoured surface. The tooling system also including means ( 7 ) for mounting an element to a support rail ( 5 ) which extends across the array, which means allows adjustment of the height of the element with respect to other elements of the array, and extends through the support rail into a space defined below the support rail. A supporting element ( 6 ) formed from a suitable resistant material and including accommodation means ( 8 ) for the means for mounting, is located in the space below the support rail and is sized so that it substantially vertically fills the space between the support rail and a base on which the tooling system is located.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a component for use in a toolingsystem, and to an improved tooling system, including said component.

2. Description of the Prior Art And Related Information

The component is particularly suitable for use in the tooling systemsgenerally described and claimed in PCT Patent Publication No. WO2002/064308. This Patent document provides a description of the basetechnology for a tooling system from which the invention of the currentPatent Application is generated.

This PCT Patent Application describes a tooling system comprising aplurality of elements generally arranged in an array, each element ofthe array being moveable longitudinally of its length relative to theother elements of the array. The tooling system also includes means toadjust the longitudinal position of a respective element so that thearray defines a desired surface contour; and means for retaining theelements in position. Each element of the array including a first endthat is machinable and is removably mounted to a base portion and theelements are arranged so that the machinable portion of the/or eachelement can be machined to produce a desired surface contour. Furtherthe elements of the array may be moved between a closed position inwhich the elements contact one another and are secured in position, andan open position in which the elements of the array are spaced apart tofacilitate the machining of the machinable portion, and each element iscapable of vertical movement relative to the surrounding elements. Drivemeans for opening and closing the array and elements with respect tosupport rails may be located in the space below the elements of thearray.

The array may comprise the whole of the tooling surface or may comprisea section of the tooling surface with the whole tooling surface beingmade up of a number of the sections.

Within each array, or section of the array, the elements may be held inconfiguration by means of a bolster, for example of the type asdescribed and claimed in co-pending Patent Publication No. WO2005/61147.

The support rails supporting the elements in the array form a series ofrails running across the array, or a section of the array. The supportrails are supported at the edges of the array, or at the edges of thesection, no support is provided for the support rails in the space belowthe array, or section. The support rails are formed from a substantialbar and have spaced settings for mounting and locating the individualelements of the array, or section. Consequently, the loading placed onthe elements in use is transmitted through the mounting from theelements to the support rail.

The above-mentioned tooling system has a principal use in the productionof moulding surfaces, for example, injection moulding surfaces.Typically, injection moulding may have an operating pressure or load inthe region of 500 bar to 2000 bar and therefore a heavy loading will beplaced on the moulding surface. With the present tooling system thisloading, or pressure, will be transmitted through the elements of thearray and the support systems. The support elements and the support railwill be placed under significant loading and this will mean a heavy loador bending force is applied to the support rail. The longer the supportrail the higher is the bending force and the result could be that somedeformation of the support rail leading to inaccuracies or anomalies inthe mould surface. This, as will be appreciated, is not desirable.

SUMMARY OF THE INVENTION

In accordance with a first aspect of the present invention, there isprovided a tooling system comprising a number of elements arranged in anarray wherein one of the surfaces of the elements define a contouredsurface, or a section of a contoured surface, and which tooling systemalso includes means for mounting an element to a support rail extendingacross the array and which means allows adjustment of the height of theelement of the array with respect to the other elements of the array andthe means for mounting extends through the support rail into a spacedefined below the support rail, wherein a supporting element formed froma suitable resistant material and including accommodation means for themeans for mounting, is located in the space below the support rail andis sized so that it substantially vertically tills the space between thesupport rail and a base on which the tooling system is located.

The provision of the supporting element in the space so that itsubstantially vertically fills the space below the support rail orsupport rails, in effect means that the supporting element is aninterference fit in the space, and that as loading is applied to thesupport rail, for example by the operation or use of the mould, theloading will be transmitted from the elements through the support railsto the supporting element and thereby to the base on which the toolingsystem is mounted. Therefore any tendency for deformation in the supportrail or support rails is negated and any deformation nullified.Consequently, removing the deformation in the support rail or supportrails and the mould surface will remain substantially as designed.

In one arrangement of the present invention the supporting element isformed as a single member. However, alternatively the supporting elementmay comprise a plurality of elements assembled together to form thesupporting element. The supporting element may be divided intohorizontal and/or vertical components. The components may be fixedlyinterconnected.

The selection of material from which the supporting element is formed isimportant and the selection will take into account several factorsincluding the operating conditions as well as cost and formability. Themost important factor is that the material is able to transmit theloading and pressure applied and does not simply fail when load isapplied.

In one embodiment of the invention, the supporting element is formedfrom a resilient material, such as mild steel. Consequently, the elementis readily machinable and inexpensive to produce. Alternatively, thesupporting element may be formed from a resistant material such aspolymer concrete. With this arrangement the supporting element can bereadily cast and therefore formed to a net shape.

In one configuration it is envisaged that the supporting element willincorporate additional functions, for example, the supporting elementmay also be used as a heat exchanger to withdraw or provide heat to thetooling system as a whole. If this is the case the material selectionfor the supporting element will also take account of the thermalproperties of the material, for example the coefficient of expansion andthermal conductivity, in order to ensure that the supporting elementdoes not exert undue load on the system in operation

In the conventional arrangement of the tooling system as described inthe above mentioned PCT Patent Publication No. WO 2002/064308 thesupport rail and support rails support the loading and pressuretransmitted from the elements during the operation of the toolingsystem. In one arrangement of the present invention the support rail, orselected support rails, of the tooling system may be extended downwardlyto contact the base and so provide the supporting element. The supportrail or rails may extended downwardly either as an integral member oralternatively by the addition of a secondary member fixedly located.

This arrangement of extending the support rail(s) may be used as analternative to the provision of a supporting element or alternative asan additional supporting element.

The individual elements of the array are held in vertical alignment andposition by means for mounting that connect the elements to the supportrail or support rails. In one arrangement of the present invention, themeans for mounting comprises a screw-threaded member that extendsbetween the lower surface of one of the elements and a screw-threadedbore provided in the support rail or the support rails.

With this type of arrangement the screw threaded member will extend fromthe lower surface of a respective element, through the bore and into thespace defined below the support rail or support rails Therefore, in onearrangement of the present invention, the supporting element is providedwith a network of holes corresponding to the location of the means formounting and the mounting provisions on the support rail or the supportrails.

When the tool is assembled the screw-threaded members of the means formounting are located in a respective hole. Further means may be providedin the hole to facilitate the adjustment of the height of the element inthe array.

It is envisaged that the network of holes in the supporting element willenable some flexibility in the position of the elements in the array andtherefore in operation there will be a number of spare holes that arenot in use. The spare holes may be used to house ancillary equipment,for example actuators or sensors or means to expel the elements from thearray.

Further the spare holes may be used to secure the supporting element tothe support rail or support rails. The supporting element may be securedto the support rail or support rails by means of bolts located incountersunk bores in the supporting element and a respective supportrail.

The upper surface of the supporting element may be shaped to facilitatethe operation of the tooling system. The shape imparted to the uppersurface may be sinusoidal, V-grooved, or castellated, either in one ortwo directions.

In one arrangement of the present invention the surface of thesupporting element adjacent to the support rail or support rails isprovided, with a series of grooves running side to side across thesupporting element. The grooves may form a lattice that extends in onedirection only or which extends in two directions. These grooved systemsallow automatic adjustment of the elements to be provided.

Alternative arrangements of the supporting element include:

-   -   a series of tubular members, such as cylinders, that are formed        into a lattice.    -   individual tubular members such as cylinders provided as        individual members appropriately located with respect to the        means for mounting.    -   a hollow box like member which may be tilled with a suitable        particulate material such as sand. This box like member may also        include appropriately located tubular members such as cylinders.

The supporting element may be secured in position below the supportrails with respect to the bolster that surrounds the array by suitablefixings. The fixings may comprise screw fixings that locate thesupporting element with respect to a bolster that surrounds the elementsof the array.

In accordance with a second aspect of the present invention, there isprovided a supporting element for use with the apparatus of the firstaspect of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described by way of example, with reference tothe accompanying drawings, in which:

FIG. 1 shows a schematic representation of a tooling system made inaccordance with the present invention;

FIG. 2A+B show a schematic representation of a first supporting elementmade in accordance with the present invention;

FIGS. 3A to 3C show schematic side views of alternative designs ofsupporting elements made in accordance with the present invention

FIG. 4 shows a plan view a two directional embodiment of the alternatedesign shown in FIG. 3B.

DETAILED DESCRIPTION

Now referring to FIG. 1 of the drawings, there is shown a schematicrepresentation of a tooling system generally in accordance with thepresent invention. The tooling system 1 comprises a number of elements 2formed into an array and disposed between the peripheral sidewalls 3 ofa bolster element.

Each of the elements 2 includes a machinable portion, the upper sectionof the element and a fixed portion. The elements 2 of the array aremounted to support rails 5 which extend across the array betweenopposing sidewalls 3 of the bolster by means of screw threaded bolts 7.

The screw threaded bolts 7 are fixedly mounted to the fixed portion ofthe elements and is mounted in a screw threaded bore provided in thesupport rail 5. A supporting element 6 is disposed in the space belowthe support rails 5 and rests on a base 9. The supporting element 6 alsocontacts the lower surface of the support rails 5 and is provided with anetwork of holes 8 corresponding to the mounting position for theelements of the array. The holes 8 are each provided at their ends witha counter-bored section 8 a. The counter-bored section enables thesupporting element to be fixedly mounted to the support rail by a simplenut and bolt arrangement.

Further the supporting element may be provided with side holes (notshown) which enable the supporting element to be fixedly mounted to thebolster.

In operation, the elements 2 of the array, or a portion of the array,can be spread apart into an open position, in order to better facilitateadjustment of the position of the elements 2 with respect to each other,or machining of the machinable portion of the element. In this mannerthe elements of the array may be machined individually without removalfrom the array if desired.

The operation of the array is disclosed fully in WO 2002/064308 whichdescription is incorporated herein by reference.

In use, the upper surface of the elements 2 forms the contoured surfaceof a mould 4 such as an injection moulding mould. Load is applied duringoperation of the tooling system and this load is transmitted via theelements, support rails and supporting element to the base 9. Theloading therefore does not apply a bending force to the support rail orsupport rails 5.

The supporting element 6 is shown in further detail in FIGS. 2A and 2Bof the drawings there is shown a first design of supporting element 6for location in the space below the support rail 5. The supportingelement 6 is dimensioned so as to substantially fill the space below thesupport rails 5 and above the base and also to allow ready constructionand operation of the other mechanical elements of the array.

The design of supporting element shown here is a straight forwardsupporting element formed as a simple block member, which is providedwith a network of holes 8.

When the tooling system is assembled the end section of thescrew-threaded bolts 7 will extend through and below the support rails5. The holes 8 in the supporting element are located so that the endsection of a respective bolt 7 extends into the hole 8.

Now referring to FIG. 3 of the drawings, there is shown end views ofalternative designs of supporting element 6. The locating and operationof these supporting elements is basically as described and FIG. 3 showsside views of alternate designs. The side views shown will be the samefor the single direction embodiments and the two direction embodiments.

FIG. 4 shows a plan view of the alternate configuration shown in FIG. 3Band illustrates the two direction embodiment only.

Each of the alternate designs shown in FIGS. 3A to 3C and FIG. 4 aresuitable for automatic operation of the tooling system.

1. A tooling system comprising a number of elements arranged in an arraywherein one of the surfaces of the elements defines one of a contouredsurface and a section of a contoured surface, the tooling system furthercomprising mounting means for mounting an element to at least onesupport rail extending across the array, said mounting means allowingadjustment of the height of an element of the array with respect toother elements of the array, the mounting means extending through the atleast one support rail into a space defined below the at least onesupport rail, wherein a supporting element, formed from a resistantmaterial and including accommodation means for the mounting means, islocated in the space below the at least one support rail and is sized tosubstantially vertically fill the space between the at least one supportrail and a base on which the tooling system is located.
 2. The toolingsystem of claim 1, wherein the supporting element is formed as a singlemember.
 3. The tooling system of claim 1, wherein the supporting elementcomprises a plurality of elements assembled together.
 4. The toolingsystem of claim 1, wherein the supporting element is divided into atleast one of horizontal and vertical components.
 5. The tooling systemof claim 1, wherein the components are fixedly interconnected.
 6. Thetooling system of claim 1, wherein the supporting element is formed froma resilient material.
 7. The tooling system of claim 6, wherein theresilient material includes mild steel.
 8. The tooling system of claim1, wherein the resistant material includes polymer concrete.
 9. Thetooling system of claim 1, wherein the supporting element is furtherconfigured as a heat exchanger to withdraw or provide heat to thetooling system.
 10. The tooling system of claim 1, wherein at least oneselected support rail is extended downwardly to contact the base and soprovide the supporting element.
 11. The tooling system of claim 10,wherein the at least one selected support rail is extended downwardly asan integral member.
 12. The tooling system of claim 10, wherein the atleast one selected support rail is extended through an addition of afixedly located secondary member.
 13. The tooling system of claim 1,wherein individual elements of the array are held in vertical alignmentand position by mounting means that connect the elements to the at leastone support rail.
 14. The tooling system of claim 13, wherein themounting means comprises a screw-threaded member that extends betweenthe lower surface of one of the elements and a screw-threaded boreprovided in the at least one support rail.
 15. The tooling system ofclaim 13, wherein the supporting element defines a network of holescorresponding to the location of the mounting means and the mountingprovisions on the at least one support rail.
 16. The tooling system ofclaim 15, further comprising adjustment means provided in at least oneof the holes of the network of holes to facilitate the adjustment of theheight of the element in the array.
 17. The tooling system of claim 15,wherein at least one of the holes of the network of holes is configuredto house ancillary equipment.
 18. The tooling system of claim 15,wherein at least one of the holes of the network of holes is configuredto secure the supporting element to the at least one support rail. 19.The tooling system of claim 1, wherein the supporting element is securedto the at least one support rail by bolts located in counter-bores inthe supporting element.
 20. The tooling system of claim 1, wherein anupper surface of the supporting element is shaped to facilitate theoperation of the tooling system.
 21. The tooling system of claim 20,wherein a shape imparted to the upper surface is one of sinusoidal,V-grooved, and castellated, in one or two directions.
 22. The toolingsystem of claim 1, wherein a surface of the supporting element adjacentto the at least one support rail is provided with a series of groovesrunning side to side across the supporting element.
 23. The toolingsystem claim 22, wherein the grooves form a lattice that extends in oneor two directions.
 24. The tooling system of claim 1, wherein thesupporting element is secured in position below the at least one supportrail with respect to the bolster that surrounds the array by fixings.25. The tooling system of claim 24, wherein the fixings comprise screwfixings that locate the supporting element with respect to a bolsterthat surrounds the elements of the array.